Coated abrasive disc and methods of making and using the same

ABSTRACT

A coated abrasive disc includes a disc backing and an abrasive layer disposed thereon. The abrasive layer comprises abrasive elements secured to a major surface of the disc backing by at least one binder material. The abrasive elements are disposed at contiguous intersections of horizontal and vertical lines of a rectangular grid pattern. At least 70 percent of the intersections have one of the abrasive elements disposed thereat. Each of the abrasive elements has two triangular abrasive platelets. Each one of the triangular abrasive platelets has respective top and bottom surfaces connected to each other, and separated by, three sidewalls. On a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing. The abrasive elements are arranged such that the triangular abrasive platelets in orthogonally adjacent abrasive elements have a Z-axis rotational orientation within 10 degrees of perpendicular to each other. Methods of making and using the coated abrasive disc are also disclosed.

TECHNICAL FIELD

The present disclosure broadly relates to coated abrasive discs, methods of making them, and methods of using them.

BACKGROUND

Coated abrasive discs made from triangular abrasive platelets are useful for abrading, finishing, or grinding a wide variety of materials and surfaces in the manufacturing of goods. In particular, finishing of welding beads (e.g., especially mild steel welds), flash, gates, and risers off castings by off-hand abrading with a handheld right-angle grinder is an important application for coated abrasive discs. In view of the above, there continues to be a need for improving the cost, performance, and/or life of the coated abrasive discs.

Coated abrasive articles having rotationally aligned triangular abrasive platelets are disclosed in U.S. Pat. No. 9,776,302 (Keipert). The coated abrasive articles have a plurality of triangular abrasive platelets each having a surface feature. The plurality of triangular abrasive platelets is attached to a flexible backing by a make coat comprising a resinous adhesive forming an abrasive layer. The surface features have a specified z-direction rotational orientation that occurs more frequently in the abrasive layer than would occur by a random z-direction rotational orientation of the surface feature.

SUMMARY

In one aspect, the present disclosure provides a coated abrasive disc comprising:

a disc backing;

an abrasive layer disposed on the disc backing, wherein the abrasive layer comprises abrasive elements secured to a major surface of the disc backing by at least one binder material, wherein the abrasive elements are disposed at contiguous intersections of horizontal lines and vertical lines of a rectangular grid pattern, wherein at least 70 percent of the intersections have one of the abrasive elements disposed thereat,

wherein each of the abrasive elements has two triangular abrasive platelets, wherein each of the triangular abrasive platelets has respective top and bottom surfaces connected to each other, and separated by, three sidewalls, wherein, on a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing,

wherein the abrasive elements are arranged such that the triangular abrasive platelets in orthogonally adjacent abrasive elements have a Z-axis rotational orientation within 10 degrees of perpendicular to each other.

Advantageously, coated abrasive discs according to the present disclosure are useful for off-hand abrading of mild steel (e.g., mild steel weld finishing), where they exhibit superior performance as compared to previous similar discs.

Accordingly, in a second aspect, the present disclosure provides a method of abrading a workpiece, the method comprising frictionally contacting a portion of the abrasive layer of a coated abrasive disc according to the present disclosure with the workpiece, and moving at least one of the workpiece and the abrasive article relative to the other to abrade the workpiece.

In a third aspect, the present disclosure provides a method of making a coated abrasive disc, the method comprising:

-   -   disposing a curable make layer precursor on a major surface of a         disc backing;     -   adhering abrasive elements to the curable make layer precursor,         -   wherein the abrasive elements are disposed at contiguous             intersections of horizontal lines and vertical lines of a             rectangular grid pattern, wherein at least 70 percent of the             intersections have one of the abrasive elements disposed             thereat,         -   wherein each of the abrasive elements has two triangular             abrasive platelets, wherein each of the triangular abrasive             platelets has respective top and bottom surfaces connected             to each other, and separated by, three sidewalls, wherein,             on a respective basis, one sidewall of at least 90 percent             of the triangular abrasive platelets is disposed facing and             proximate to the disc backing,         -   wherein the abrasive elements are arranged such that the             triangular abrasive platelets in orthogonally adjacent             abrasive elements have a Z-axis rotational orientation             within 10 degrees of perpendicular to each other;     -   disposing a curable size layer precursor over the at least         partially cured make layer precursor and triangular abrasive         platelets; and at least partially curing the curable size layer         precursor to provide a size layer.

As used herein:

The term “mild steel” refers to a carbon-based steel alloy containing less than about 0.25 percent by weight of carbon.

The term “offhand abrading” means abrading where the operator manually urges the disc/wheel against a workpiece or vice versa.

The term “proximate” means very near or next to (e.g., contacting or embedded in a binder layer contacting).

The term “workpiece” refers to a thing being abraded.

As used herein, the term “triangular abrasive platelet”, means a ceramic abrasive particle with at least a portion of the abrasive particle having a predetermined shape that is replicated from a mold cavity used to form the shaped precursor abrasive particle. The triangular abrasive platelet will generally have a predetermined geometric shape that substantially replicates the mold cavity that was used to form the triangular abrasive platelet. Triangular abrasive platelet as used herein excludes randomly sized abrasive particles obtained by a mechanical crushing operation.

As used herein, “Z-axis rotational orientation” refers to the angular rotation, about a Z-axis perpendicular to the major surface of the disc backing, of the longitudinal dimension the triangular abrasive platelet sidewall that most faces the disc backing.

Features and advantages of the present disclosure will be further understood upon consideration of the detailed description as well as the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic top view of exemplary coated abrasive disc 100.

FIG. 1A is an enlarged view of region 1A in FIG. 1.

FIG. 1B is a schematic side view of an exemplary coated abrasive disc 100 taken along line 1B-1B in FIG. 1A.

FIG. 2A is a schematic top view of exemplary triangular abrasive platelet 130 a.

FIG. 2B is a schematic perspective view of exemplary triangular abrasive platelet 130 a

FIG. 3A is a schematic top view of exemplary triangular abrasive platelet 330.

FIG. 3B schematic cross-sectional side view of exemplary triangular abrasive platelet 330.

FIG. 4 is a top view of an exemplary production tool 400 useful for making coated abrasive disc 100.

FIG. 4A is an enlarged view of region 4A in FIG. 4

FIG. 4B is a schematic cross-sectional view of production tool 400 taken along line 4B-4B in FIG. 4A.

FIG. 4C is a schematic cross-sectional view of production tool 400 taken along line 4C-4C in FIG. 4A.

Repeated use of reference characters in the specification and drawings is intended to represent the same or analogous features or elements of the disclosure. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the disclosure. The figures may not be drawn to scale.

DETAILED DESCRIPTION

FIG. 1 shows an exemplary coated abrasive disc 100 according to the present disclosure, wherein abrasive elements 160 are secured at precise locations and Z-axis rotational orientations to a disc backing 110.

Referring now to FIG. 1A, abrasive elements 160 each have two triangular abrasive platelets 130. Abrasive elements 160 are disposed at contiguous intersections 190 of horizontal lines 192 and vertical lines 194 of a rectangular grid pattern 196. At least 70 percent of the contiguous intersections 190 have one of the abrasive elements 160 disposed thereat.

Abrasive elements 160 are arranged such that the triangular abrasive platelets 130 in orthogonally adjacent abrasive elements 160 have a Z-axis rotational orientation within 10 degrees of perpendicular to each other.

Referring now to FIG. 1B, coated abrasive disc 100 comprises abrasive layer 120 disposed on major surface 115 of disc backing 110. Abrasive layer 120 comprises abrasive elements 160, each having two triangular abrasive platelets 130 secured to major surface 115 by at least one binder material 140 (shown as make layer 142 and size layer 144). Optional supersize layer 146 is disposed on size layer 144.

Referring now to FIGS. 2A and 2B, each triangular abrasive platelet 130 a has respective top and bottom surfaces (132, 134) connected to each other, and separated by, three sidewalls (136 a, 136 b, 136 c).

FIGS. 3A and 3B show another embodiment of a useful triangular abrasive platelet 330, triangular abrasive platelet 330 has respective top and bottom surfaces (332, 334) connected to each other, and separated by, three sloping sidewalls (336).

The disc backing may comprise any known coated abrasive backing, for example. In some embodiments, the disc backing comprises a continuous uninterrupted disc, while in others it may have a central arbor hole for mounting. Likewise, the disc backing may be flat or it may have a depressed central hub, for example, a Type 27 depressed center disc. The disc backing may be rigid, semi-rigid, or flexible. In some embodiments, the backing has a mechanical fastener, or adhesive fastener securely attached to a major surface opposite the abrasive layer. Suitable materials for the substrate include polymeric films, metal foils, woven fabrics, knitted fabrics, paper, vulcanized fiber, nonwovens, foams, screens, laminates, combinations thereof, and treated versions thereof. For off-hand grinding applications where stiffness and cost are concerns, vulcanized fiber backings are typically preferred. For applications where stiffness of the backing is desired, a flexible backing may also be used by affixing it to a rigid backup pad mounted to the grinding tool.

The disc backing is generally circular and preferably rotationally symmetric around its center. Preferably it has a circular perimeter, but it may have additional features along the perimeter such as, for example, in the case of a scalloped perimeter.

The abrasive layer may comprise a single binder layer having abrasive particles retained therein, or more typically, a multilayer construction having make and size layers. Coated abrasive discs according to the present disclosure may include additional layers such as, for example, an optional supersize layer that is superimposed on the abrasive layer, or a backing antistatic treatment layer may also be included, if desired. Exemplary suitable binders can be prepared from thermally curable resins, radiation-curable resins, and combinations thereof.

The make layer can be formed by coating a curable make layer precursor onto a major surface of the backing. The make layer precursor may comprise, for example, glue, phenolic resin, aminoplast resin, urea-formaldehyde resin, melamine-formaldehyde resin, urethane resin, free-radically polymerizable polyfunctional (meth)acrylate (e.g., aminoplast resin having pendant α,β-unsaturated groups, acrylated urethane, acrylated epoxy, acrylated isocyanurate), epoxy resin (including bis-maleimide and fluorene-modified epoxy resins), isocyanurate resin, and mixtures thereof. Of these, phenolic resins are preferred, especially when used in combination with a vulcanized fiber backing.

Phenolic resins are generally formed by condensation of phenol and formaldehyde, and are usually categorized as resole or novolac phenolic resins. Novolac phenolic resins are acid-catalyzed and have a molar ratio of formaldehyde to phenol of less than 1:1. Resole (also resol) phenolic resins can be catalyzed by alkaline catalysts, and the molar ratio of formaldehyde to phenol is greater than or equal to one, typically between 1.0 and 3.0, thus presenting pendant methylol groups. Alkaline catalysts suitable for catalyzing the reaction between aldehyde and phenolic components of resole phenolic resins include sodium hydroxide, barium hydroxide, potassium hydroxide, calcium hydroxide, organic amines, and sodium carbonate, all as solutions of the catalyst dissolved in water.

Resole phenolic resins are typically coated as a solution with water and/or organic solvent (e.g., alcohol). Typically, the solution includes about 70 percent to about 85 percent solids by weight, although other concentrations may be used. If the solids content is very low, then more energy is required to remove the water and/or solvent. If the solids content is very high, then the viscosity of the resulting phenolic resin is too high which typically leads to processing problems.

Phenolic resins are well-known and readily available from commercial sources. Examples of commercially available resole phenolic resins useful in practice of the present disclosure include those marketed by Durez Corporation under the trade designation VARCUM (e.g., 29217, 29306, 29318, 29338, 29353); those marketed by Ashland Chemical Co. of Bartow, Fla. under the trade designation AEROFENE (e.g., AEROFENE 295); and those marketed by Kangnam Chemical Company Ltd. of Seoul, South Korea under the trade designation PHENOLITE (e.g., PHENOLITE TD-2207).

The make layer precursor may be applied by any known coating method for applying a make layer to a backing such as, for example, including roll coating, extrusion die coating, curtain coating, knife coating, gravure coating, and spray coating.

The basis weight of the make layer utilized may depend, for example, on the intended use(s), type(s) of abrasive particles, and nature of the coated abrasive disc being prepared, but typically will be in the range of from 1, 2, 5, 10, or 15 grams per square meter (gsm) to 20, 25, 100, 200, 300, 400, or even 600 gsm. The make layer may be applied by any known coating method for applying a make layer (e.g., a make coat) to a backing, including, for example, roll coating, extrusion die coating, curtain coating, knife coating, gravure coating, and spray coating.

Once the make layer precursor is coated on the backing, the triangular abrasive platelets are applied to and adhered to (e.g., embedded in) the make layer precursor. The triangular abrasive platelets are applied nominally according to a predetermined pattern and Z-axis rotational orientation onto the make layer precursor.

In some preferred embodiments, the horizontal and/or vertical spacing between the abrasive elements is from 1 to 3 times, and more preferably 1.2 to 2 times the average length of the sidewalls of the triangular abrasive platelets that are facing the fiber disc backing, although other spacings may also be used.

One sidewall of at least 90 percent (e.g., at least 95 percent, at least 99 percent, or even 100 percent) of each one of the triangular abrasive platelets is disposed facing (and preferably proximate to) the disc backing. Further, a sidewall that is disposed facing the disc backing has a Z-axis rotational orientation (i.e., has a longitudinal Z-axis rotational orientation) that is within 10 degrees (preferably within 5 degrees, and more preferably within 2 degrees) of the vertical lines or horizontal, depending on their location. In this regard, the Z-axis rotational direction of a sidewall facing the backing is considered to be within 10 degrees of the vertical lines if its Z-axis projection onto the rectangular grid pattern (which is planar) intersects at least one of the vertical lines at an angle of 10 degrees or less (including collinear). Likewise, the Z-axis rotational direction of a sidewall facing the backing is considered to be within 10 degrees of the horizontal lines if its Z-axis projection onto the rectangular grid pattern (which is planar) intersects at least one of the horizontal lines at an angle of 10 degrees or less (including collinear).

The triangular abrasive platelets have sufficient hardness to function as abrasive particles in abrading processes. Preferably, the triangular abrasive platelets have a Mohs hardness of at least 4, at least 5, at least 6, at least 7, or even at least 8. Preferably, they comprise alpha alumina.

In some embodiments, the triangular abrasive platelets are shaped as thin triangular prisms, while in other embodiments the triangular abrasive platelets are shaped as truncated triangular pyramids (preferably with a taper angle of about 8 degrees). The triangular abrasive platelets may have different side lengths, but are preferably equilateral on their largest face.

Crushed abrasive or non-abrasive particles may be included in the abrasive layer in addition to the abrasive elements and/or abrasive platelets, preferably in sufficient quantity to form a closed coat (i.e., substantially the maximum possible number of abrasive particles of nominal specified grade(s) that can be retained in the abrasive layer).

Examples of suitable abrasive particles include: fused aluminum oxide; heat-treated aluminum oxide; white fused aluminum oxide; ceramic aluminum oxide materials such as those commercially available under the trade designation 3M CERAMIC ABRASIVE GRAIN from 3M Company, St. Paul, Minn.; brown aluminum oxide; blue aluminum oxide; silicon carbide (including green silicon carbide); titanium diboride; boron carbide; tungsten carbide; garnet; titanium carbide; diamond; cubic boron nitride; garnet; fused alumina zirconia; iron oxide; chromia; zirconia; titania; tin oxide; quartz; feldspar; flint; emery; sol-gel-derived abrasive particles; and combinations thereof. Of these, molded sol-gel derived alpha alumina triangular abrasive platelets are preferred in many embodiments. Abrasive material that cannot be processed by a sol-gel route may be molded with a temporary or permanent binder to form shaped precursor particles which are then sintered to form triangular abrasive platelets, for example, as described in U.S. Pat. Appln. Publ. No. 2016/0068729 A1 (Erickson et al.).

Examples of sol-gel-derived abrasive particles and methods for their preparation can be found in U.S. Pat. No. 4,314,827 (Leitheiser et al.); U.S. Pat. No. 4,623,364 (Cottringer et al.); U.S. Pat. No. 4,744,802 (Schwabel), U.S. Pat. No. 4,770,671 (Monroe et al.); and U.S. Pat. No. 4,881,951 (Monroe et al.). It is also contemplated that the abrasive particles could comprise abrasive agglomerates such, for example, as those described in U.S. Pat. No. 4,652,275 (Bloecher et al.) or U.S. Pat. No. 4,799,939 (Bloecher et al.). In some embodiments, the triangular abrasive platelets may be surface-treated with a coupling agent (e.g., an organosilane coupling agent) or other physical treatment (e.g., iron oxide or titanium oxide) to enhance adhesion of the abrasive particles to the binder (e.g., make and/or size layer). The abrasive particles may be treated before combining them with the corresponding binder precursor, or they may be surface treated in situ by including a coupling agent to the binder.

Preferably, the triangular abrasive platelets comprise ceramic abrasive particles such as, for example, sol-gel-derived polycrystalline alpha alumina particles. Triangular abrasive platelets composed of crystallites of alpha alumina, magnesium alumina spinel, and a rare earth hexagonal aluminate may be prepared using sol-gel precursor alpha alumina particles according to methods described in, for example, U.S. Pat. No. 5,213,591 (Celikkaya et al.) and U.S. Pat. Appln. Publ. Nos. 2009/0165394 A1 (Culler et al.) and 2009/0169816 A1 (Erickson et al.).

Alpha alumina-based triangular abrasive platelets can be made according to well-known multistep processes. Briefly, the method comprises the steps of making either a seeded or non-seeded sol-gel alpha alumina precursor dispersion that can be converted into alpha alumina; filling one or more mold cavities having the desired outer shape of the triangular abrasive platelet with the sol-gel, drying the sol-gel to form precursor triangular abrasive platelets; removing the precursor triangular abrasive platelets from the mold cavities; calcining the precursor triangular abrasive platelets to form calcined, precursor triangular abrasive platelets, and then sintering the calcined, precursor triangular abrasive platelets to form triangular abrasive platelets. The process will now be described in greater detail.

Further details concerning methods of making sol-gel-derived abrasive particles can be found in, for example, U.S. Pat. No. 4,314,827 (Leitheiser); U.S. Pat. No. 5,152,917 (Pieper et al.); U.S. Pat. No. 5,435,816 (Spurgeon et al.); U.S. Pat. No. 5,672,097 (Hoopman et al.); U.S. Pat. No. 5,946,991 (Hoopman et al.); U.S. Pat. No. 5,975,987 (Hoopman et al.); and U.S. Pat. No. 6,129,540 (Hoopman et al.); and in U.S. Publ. Pat. Appln. No. 2009/0165394 A1 (Culler et al.).

The triangular abrasive platelets may include a single kind of triangular abrasive platelets or a blend of two or more sizes and/or compositions of triangular abrasive platelets. In some preferred embodiments, the triangular abrasive platelets are precisely-shaped in that individual triangular abrasive platelets will have a shape that is essentially the shape of the portion of the cavity of a mold or production tool in which the particle precursor was dried, prior to optional calcining and sintering.

Triangular abrasive platelets used in the present disclosure can typically be made using tools (i.e., molds) cut using precision machining, which provides higher feature definition than other fabrication alternatives such as, for example, stamping or punching. Typically, the cavities in the tool surface have planar faces that meet along sharp edges, and form the sides and top of a truncated pyramid. The resultant triangular abrasive platelets have a respective nominal average shape that corresponds to the shape of cavities (e.g., truncated pyramid) in the tool surface; however, variations (e.g., random variations) from the nominal average shape may occur during manufacture, and triangular abrasive platelets exhibiting such variations are included within the definition of triangular abrasive platelets as used herein.

In some embodiments, the base and the top of the triangular abrasive platelets are substantially parallel, resulting in prismatic or truncated pyramidal shapes, although this is not a requirement. In some embodiments, the sides of a truncated trigonal pyramid have equal dimensions and form dihedral angles with the base of about 82 degrees. However, it will be recognized that other dihedral angles (including 90 degrees) may also be used. For example, the dihedral angle between the base and each of the sides may independently range from 45 to 90 degrees, typically 70 to 90 degrees, more typically 75 to 85 degrees.

As used herein in referring to triangular abrasive platelets, the term “length” refers to the maximum dimension of a triangular abrasive platelet. “Width” refers to the maximum dimension of the triangular abrasive platelet that is perpendicular to the length. The terms “thickness” or “height” refer to the dimension of the triangular abrasive platelet that is perpendicular to the length and width.

Examples of sol-gel-derived triangular alpha alumina (i.e., ceramic) abrasive particles can be found in U.S. Pat. No. 5,201,916 (Berg); U.S. Pat. No. 5,366,523 (Rowenhorst (Re 35,570)); and U.S. Pat. No. 5,984,988 (Berg). Details concerning such abrasive particles and methods for their preparation can be found, for example, in U.S. Pat. No. 8,142,531 (Adefris et al.); U.S. Pat. No. 8,142,891 (Culler et al.); and U.S. Pat. No. 8,142,532 (Erickson et al.); and in U.S. Pat. Appl. Publ. Nos. 2012/0227333 (Adefris et al.); 2013/0040537 (Schwabel et al.); and 2013/0125477 (Adefris).

The triangular abrasive platelets are typically selected to have a length in a range of from 1 micron to 15000 microns, more typically 10 microns to about 10000 microns, and still more typically from 150 to 2600 microns, although other lengths may also be used.

Triangular abrasive platelets are typically selected to have a width in a range of from 0.1 micron to 3500 microns, more typically 100 microns to 3000 microns, and more typically 100 microns to 2600 microns, although other lengths may also be used.

Triangular abrasive platelets are typically selected to have a thickness in a range of from 0.1 micron to 1600 microns, more typically from 1 micron to 1200 microns, although other thicknesses may be used.

In some embodiments, triangular abrasive platelets may have an aspect ratio (length to thickness) of at least 2, 3, 4, 5, 6, or more.

Surface coatings on the triangular abrasive platelets may be used to improve the adhesion between the triangular abrasive platelets and a binder in abrasive articles, or can be used to aid in electrostatic deposition of the triangular abrasive platelets. In one embodiment, surface coatings as described in U.S. Pat. No. 5,352,254 (Celikkaya) in an amount of 0.1 to 2 percent surface coating to triangular abrasive platelet weight may be used. Such surface coatings are described in U.S. Pat. No. 5,213,591 (Celikkaya et al.); U.S. Pat. No. 5,011,508 (Wald et al.); U.S. Pat. No. 1,910,444 (Nicholson); U.S. Pat. No. 3,041,156 (Rowse et al.); U.S. Pat. No. 5,009,675 (Kunz et al.); U.S. Pat. No. 5,085,671 (Martin et al.); U.S. Pat. No. 4,997,461 (Markhoff-Matheny et al.); and U.S. Pat. No. 5,042,991 (Kunz et al.). Additionally, the surface coating may prevent the triangular abrasive platelet from capping. Capping is the term to describe the phenomenon where metal particles from the workpiece being abraded become welded to the tops of the triangular abrasive platelets. Surface coatings to perform the above functions are known to those of skill in the art.

The abrasive particles may be independently sized according to an abrasives industry recognized specified nominal grade. Exemplary abrasive industry recognized grading standards include those promulgated by ANSI (American National Standards Institute), FEPA (Federation of European Producers of Abrasives), and JIS (Japanese Industrial Standard). ANSI grade designations (i.e., specified nominal grades) include, for example: ANSI 4, ANSI 6, ANSI 8, ANSI 16, ANSI 24, ANSI 36, ANSI 46, ANSI 54, ANSI 60, ANSI 70, ANSI 80, ANSI 90, ANSI 100, ANSI 120, ANSI 150, ANSI 180, ANSI 220, ANSI 240, ANSI 280, ANSI 320, ANSI 360, ANSI 400, and ANSI 600. FEPA grade designations include F4, F5, F6, F7, F8, F10, F12, F14, F16, F16, F20, F22, F24, F30, F36, F40, F46, F54, F60, F70, F80, F90, F100, F120, F150, F180, F220, F230, F240, F280, F320, F360, F400, F500, F600, F800, F1000, F1200, F1500, and F2000. JIS grade designations include JIS8, JIS12, JIS16, JIS24, JIS36, JIS46, JIS54, JIS60, JIS80, JIS100, JIS150, JIS180, JIS220, JIS240, JIS280, JIS320, JIS360, JIS400, JIS600, JIS800, JIS1000, JIS1500, JIS2500, JIS4000, JIS6000, JIS8000, and JIS10000. According to one embodiment of the present disclosure, the average diameter of the abrasive particles may be within a range of from 260 to 1400 microns in accordance with FEPA grades F60 to F24.

Alternatively, the abrasive particles can be graded to a nominal screened grade using U.S.A. Standard Test Sieves conforming to ASTM E-11 “Standard Specification for Wire Cloth and Sieves for Testing Purposes”. ASTM E-11 prescribes the requirements for the design and construction of testing sieves using a medium of woven wire cloth mounted in a frame for the classification of materials according to a designated particle size. A typical designation may be represented as −18+20 meaning that the abrasive particles pass through a test sieve meeting ASTM E-11 specifications for the number 18 sieve and are retained on a test sieve meeting ASTM E-11 specifications for the number 20 sieve. In one embodiment, the abrasive particles have a particle size such that most of the particles pass through an 18 mesh test sieve and can be retained on a 20, 25, 30, 35, 40, 45, or 50 mesh test sieve. In various embodiments, the abrasive particles can have a nominal screened grade of: −18+20, −20/+25, −25+30, −30+35, −35+40, 5−40+45, −45+50, −50+60, −60+70, −70/+80, −80+100, −100+120, −120+140, −140+170, −170+200, −200+230, −230+270, −270+325, −325+400, −400+450, −450+500, or −500+635. Alternatively, a custom mesh size can be used such as −90+100.

Referring again to FIG. 1A, rectangular grid pattern 196 is formed by vertical lines 194 (extending in a vertical direction) and horizontal lines 192 (extending in a horizontal direction), which are by definition perpendicular to the vertical lines. The spacing of the vertical lines and/or horizontal lines may be regular or irregular. Preferably, it is regular in both the vertical and horizontal directions. Preferably, the vertical and horizontal spacing is identical. For example, in some preferred embodiments, the regular vertical spacing (i.e., vertical pitch) between triangular abrasive platelets may be between 1.2 and 2 times the platelet length and the regular horizontal spacing (i.e., horizontal pitch) between triangular abrasive platelets between 1.2 and 2 times the platelet length. Of course, these spacings may vary depending on the size and thickness of the triangular abrasive platelets.

In some preferred embodiments, the vertical and horizontal pitch is from 1 to 6 times, more preferably 2 to 5 times, and even more preferably 3 to 5 times the thickness of the triangular abrasive particles.

Coated abrasive discs according to the present disclosure can be made by a method in which the triangular abrasive platelets are precisely placed and oriented. The method generally involves the steps of filling the cavities in a production tool each with one or more triangular abrasive platelets (typically one or two), aligning the filled production tool and a make layer precursor-coated backing for transfer of the triangular abrasive platelets to the make layer precursor, transferring the abrasive particles from the cavities onto the make layer precursor-coated backing, and removing the production tool from the aligned position. Thereafter, the make layer precursor is at least partially cured (typically to a sufficient degree that the triangular abrasive platelets are securely adhered to the backing), a size layer precursor is then applied over the make layer precursor and abrasive particles, and at least partially cured to provide the coated abrasive disc. The process, which may be batch or continuous, can be practiced by hand or automated, e.g., using robotic equipment. It is not required to perform all steps or perform them in consecutive order, but they can be performed in the order listed or additional steps performed in between.

The triangular abrasive platelets can be placed in the desired Z-axis rotational orientation formed by first placing them in appropriately shaped cavities in a dispensing surface of a production tool arranged to have a complementary rectangular grid pattern.

An exemplary production tool 400 for making the coated abrasive disc 100 shown in FIGS. 1 and 1A-1C, formed by casting a thermoplastic sheet, is shown in FIGS. 4 and 4A-4C. Referring now to FIGS. 4 and 4A-4C, production tool 400 has a dispensing surface 410 comprising a rectangular array 430 of paired cavities 420 sized and shaped to receive the triangular abrasive platelets. Cavities 420 have a Z-axis rotational orientation so that when filled with triangular abrasive platelets that when they are subsequently transferred they form the desired corresponding to the rectangular array pattern and Z-axis rotational orientation in the resultant coated abrasive disc shown in FIG. 1.

Once most, or all, of the cavities are filled with the desired number of triangular abrasive platelets the dispensing surface is brought into close proximity or contact with the make layer precursor layer on the disc backing thereby embedding and transferring the triangular abrasive platelets from the production tool to the make layer precursor while nominally maintaining horizontal orientation. Of course, some unintended loss of orientation may occur, but it should generally be manageable within the ±10 degree or less tolerance.

In some embodiments, the depth of the cavities in the production tool is selected such that the triangular abrasive platelets fit entirely within the cavities. In some preferred embodiments, the triangular abrasive platelets extend slightly beyond the openings of the cavities. In this way, they can be transferred to the make layer precursor by direct contact with reduced chance of resin transfer to the to the production tool. In some preferred embodiments, the center of mass for each triangular abrasive platelet resides within a respective cavity of the production tool when the triangular abrasive platelet is fully inserted into the cavity. If the depth of the cavities becomes too short, with the triangular abrasive platelet's center of mass being located outside of the cavity, the triangular abrasive platelets are not readily retained within the cavities and may jump back out as the production tool is used in the apparatus.

In order to fill the cavities in the production tool, an excess of the triangular abrasive platelets is preferably applied to the dispensing surface of the production tool such that more triangular abrasive platelets are provided than the number of cavities. An excess of triangular abrasive platelets, which means that there are more triangular abrasive platelets present per unit length of the production tool than cavities present, helps to ensure that most cavities within the production tool are eventually filled with a triangular abrasive platelet as the triangular abrasive platelets accumulate onto the dispensing surface and are moved about either due to gravity or other mechanically applied forces to translate them into a cavity. Since the bearing area and spacing of the abrasive particles is often designed into the production tooling for the specific grinding application, it is generally desirable to not have too much variability in the number of unfilled cavities.

Preferably, a majority of the cavities in the dispensing surface are filled with a triangular abrasive platelet disposed in an individual cavity such that the sides of the cavity and platelet are at least approximately parallel. This can be accomplished by shaping the cavities slightly larger than the triangular abrasive platelets (or multiple thereof). To facilitate filling and release it may be desirable that the cavities have inwardly sloping sidewalls with increasing depth and/or have vacuum openings at the bottoms of the cavities, wherein the vacuum opening lead to a vacuum source. It is desirable to transfer the triangular abrasive platelets onto the make layer precursor-coated backing such that they stand up or are erectly applied. Therefore, the cavity shape is designed to hold the triangular abrasive platelet erectly.

In various embodiments, at least 60, 70, 80, 90, or 95 percent of the cavities in the dispensing surface contain a triangular abrasive platelet. In some embodiments, gravity can be used to fill the cavities. In other embodiments, the production tool can be inverted and vacuum applied to hold the triangular abrasive platelets in the cavities. The triangular abrasive platelets can be applied by spray, fluidized bed (air or vibration), or electrostatic coating, for example. Removal of excess triangular abrasive platelets would be done by gravity as any abrasive particles not retained would fall back down. The triangular abrasive platelets can thereafter be transferred to the make layer precursor-coated disc backing by removing vacuum.

As mentioned above, excess triangular abrasive platelets may be supplied than cavities such that some will remain on the dispensing surface after the desired number of cavities have been filled. These excess triangular abrasive platelets can often be blown, wiped, or otherwise removed from the dispensing surface. For example, a vacuum or other force could be applied to hold the triangular abrasive platelets in the cavities and the dispensing surface inverted to clear it of the remaining fraction of the excess triangular abrasive platelets.

After substantially all the cavities in the dispensing surface of the production tool are filled with the triangular abrasive platelets, the dispensing surface of the production tool is brought into proximity with the make layer precursor.

In preferred embodiments, the production tool is formed of a thermoplastic polymer such as, for example, polyethylene, polypropylene, polyester, or polycarbonate from a metal master tool. Fabrication methods of production tools, and of master tooling used in their manufacture, can be found in, for example, U.S. Pat. No. 5,152,917 (Pieper et al.); U.S. Pat. No. 5,435,816 (Spurgeon et al.); U.S. Pat. No. 5,672,097 (Hoopman et al.); U.S. Pat. No. 5,946,991 (Hoopman et al.); U.S. Pat. No. 5,975,987 (Hoopman et al.); and U.S. Pat. No. 6,129,540 (Hoopman et al.); and U.S. Pat. Appl. Publ. Nos. 2013/0344786 A1 (Keipert) and 2016/0311084 A1 (Culler et al.).

In some preferred embodiments, the production tool is manufactured using additive manufacturing or “3-D printing” techniques.

Once the triangular abrasive platelets have been embedded in the make layer precursor, it is at least partially cured in order to preserve orientation of the mineral during application of the size layer precursor. Typically, this involves B-staging the make layer precursor, but more advanced cures may also be used if desired. B-staging may be accomplished, for example, using heat and/or light and/or use of a curative, depending on the nature of the make layer precursor selected.

Next, the size layer precursor is applied over the at least partially cured make layer precursor and triangular abrasive platelets. The size layer can be formed by coating a curable size layer precursor onto a major surface of the backing. The size layer precursor may comprise, for example, glue, phenolic resin, aminoplast resin, urea-formaldehyde resin, melamine-formaldehyde resin, urethane resin, free-radically polymerizable polyfunctional (meth)acrylate (e.g., aminoplast resin having pendant α,β-unsaturated groups, acrylated urethane, acrylated epoxy, acrylated isocyanurate), epoxy resin (including bis-maleimide and fluorene-modified epoxy resins), isocyanurate resin, and mixtures thereof. If phenolic resin is used to form the make layer, it is likewise preferably used to form the size layer. The size layer precursor may be applied by any known coating method for applying a size layer to a backing, including roll coating, extrusion die coating, curtain coating, knife coating, gravure coating, spray coating, and the like. If desired, a presize layer precursor or make layer precursor according to the present disclosure may be also used as the size layer precursor.

The basis weight of the size layer will also necessarily vary depending on the intended use(s), type(s) of abrasive particles, and nature of the coated abrasive disc being prepared, but generally will be in the range of from 1 or 5 gsm to 300, 400, or even 500 gsm, or more. The size layer precursor may be applied by any known coating method for applying a size layer precursor (e.g., a size coat) to a backing including, for example, roll coating, extrusion die coating, curtain coating, and spray coating

Once applied, the size layer precursor, and typically the partially cured make layer precursor, are sufficiently cured to provide a usable coated abrasive disc. In general, this curing step involves thermal energy, although other forms of energy such as, for example, radiation curing may also be used. Useful forms of thermal energy include, for example, heat and infrared radiation. Exemplary sources of thermal energy include ovens (e.g., festoon ovens), heated rolls, hot air blowers, infrared lamps, and combinations thereof.

In addition to other components, binder precursors, if present, in the make layer precursor and/or presize layer precursor of coated abrasive discs according to the present disclosure may optionally contain catalysts (e.g., thermally activated catalysts or photocatalysts), free-radical initiators (e.g., thermal initiators or photoinitiators), curing agents to facilitate cure. Such catalysts (e.g., thermally activated catalysts or photocatalysts), free-radical initiators (e.g., thermal initiators or photoinitiators), and/or curing agents may be of any type known for use in coated abrasive discs including, for example, those described herein.

In addition to other components, the make and size layer precursors may further contain optional additives, for example, to modify performance and/or appearance. Exemplary additives include grinding aids, fillers, plasticizers, wetting agents, surfactants, pigments, coupling agents, fibers, lubricants, thixotropic materials, antistatic agents, suspending agents, and/or dyes.

Exemplary grinding aids, which may be organic or inorganic, include waxes, halogenated organic compounds such as chlorinated waxes like tetrachloronaphthalene, pentachloronaphthalene, and polyvinyl chloride; halide salts such as sodium chloride, potassium cryolite, sodium cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluorides, potassium chloride, magnesium chloride; and metals and their alloys such as tin, lead, bismuth, cobalt, antimony, cadmium, iron, and titanium. Examples of other grinding aids include sulfur, organic sulfur compounds, graphite, and metallic sulfides. A combination of different grinding aids can be used.

Exemplary antistatic agents include electrically conductive material such as vanadium pentoxide (e.g., dispersed in a sulfonated polyester), humectants, carbon black and/or graphite in a binder.

Examples of useful fillers for this disclosure include silica such as quartz, glass beads, glass bubbles and glass fibers; silicates such as talc, clays, (montmorillonite) feldspar, mica, calcium silicate, calcium metasilicate, sodium aluminosilicate, sodium silicate; metal sulfates such as calcium sulfate, barium sulfate, sodium sulfate, aluminum sodium sulfate, aluminum sulfate; gypsum; vermiculite; wood flour; aluminum trihydrate; carbon black; aluminum oxide; titanium dioxide; cryolite; chiolite; and metal sulfites such as calcium sulfite.

Optionally a supersize layer may be applied to at least a portion of the size layer. If present, the supersize typically includes grinding aids and/or anti-loading materials. The optional supersize layer may serve to prevent or reduce the accumulation of swarf (the material abraded from a workpiece) between abrasive particles, which can dramatically reduce the cutting ability of the coated abrasive disc. Useful supersize layers typically include a grinding aid (e.g., potassium tetrafluoroborate), metal salts of fatty acids (e.g., zinc stearate or calcium stearate), salts of phosphate esters (e.g., potassium behenyl phosphate), phosphate esters, urea-formaldehyde resins, mineral oils, crosslinked silanes, crosslinked silicones, and/or fluorochemicals. Useful supersize materials are further described, for example, in U.S. Pat. No. 5,556,437 (Lee et al.). Typically, the amount of grinding aid incorporated into coated abrasive products is about 50 to about 400 gsm, more typically about 80 to about 300 gsm. The supersize may contain a binder such as for example, those used to prepare the size or make layer, but it need not have any binder.

Further details concerning coated abrasive discs comprising an abrasive layer secured to a backing, wherein the abrasive layer comprises abrasive particles and make, size, and optional supersize layers are well known, and may be found, for example, in U.S. Pat. No. 4,734,104 (Broberg); U.S. Pat. No. 4,737,163 (Larkey); U.S. Pat. No. 5,203,884 (Buchanan et al.); U.S. Pat. No. 5,152,917 (Pieper et al.); U.S. Pat. No. 5,378,251 (Culler et al.); U.S. Pat. No. 5,417,726 (Stout et al.); U.S. Pat. No. 5,436,063 (Follett et al.); U.S. Pat. No. 5,496,386 (Broberg et al.); U.S. Pat. No. 5,609,706 (Benedict et al.); U.S. Pat. No. 5,520,711 (Helmin); U.S. Pat. No. 5,954,844 (Law et al.); U.S. Pat. No. 5,961,674 (Gagliardi et al.); U.S. Pat. No. 4,751,138 (Bange et al.); U.S. Pat. No. 5,766,277 (DeVoe et al.); U.S. Pat. No. 6,077,601 (DeVoe et al.); U.S. Pat. No. 6,228,133 (Thurber et al.); and U.S. Pat. No. 5,975,988 (Christianson).

Coated abrasive discs according to the present disclosure are useful for abrading a workpiece; for example, by off-hand abrading with a handheld right-angle grinder. Preferred workpieces include welding beads (e.g., especially mild steel welds), flash, gates, and risers off castings.

Select Embodiments of the Present Disclosure

In a first embodiment, the present disclosure provides a coated abrasive disc comprising:

a disc backing;

an abrasive layer disposed on the disc backing, wherein the abrasive layer comprises abrasive elements secured to a major surface of the disc backing by at least one binder material, wherein the abrasive elements are disposed at contiguous intersections of horizontal lines and vertical lines of a rectangular grid pattern, wherein at least 70 percent (preferably at least 75 percent, more preferably at least 80 percent, more preferably at least 85 percent, and more preferably even at least 90 percent) of the intersections have one of the abrasive elements disposed thereat,

wherein each of the abrasive elements has two triangular abrasive platelets, wherein each of the triangular abrasive platelets has respective top and bottom surfaces connected to each other, and separated by, three sidewalls, wherein, on a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing,

wherein the abrasive elements are arranged such that the triangular abrasive platelets in orthogonally adjacent abrasive elements have a Z-axis rotational orientation within 10 degrees of perpendicular to each other.

In a second embodiment, the present disclosure provides a coated abrasive disc according to the first embodiment, wherein at least 80 percent of the intersections have one of the abrasive elements disposed thereat.

In a third embodiment, the present disclosure provides a coated abrasive disc according to the first or second embodiment, wherein, on a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing, wherein the triangular abrasive platelets disposed adjacent to alternating intersections along each horizontal line have a Z-axis rotational orientation within 5 degrees of the horizontal lines, and wherein the triangular abrasive platelets disposed adjacent to alternating intersections along each vertical line have a Z-axis rotational orientation within 5 degrees of the vertical lines.

In a fourth embodiment, the present disclosure provides a coated abrasive disc according to any one of the first to third embodiments, wherein, on a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing, wherein the triangular abrasive platelets disposed adjacent to alternating intersections along each horizontal line have a Z-axis rotational orientation within 2 degrees of the horizontal lines, and wherein the triangular abrasive platelets disposed adjacent to alternating intersections along each vertical line have a Z-axis rotational orientation within 2 degrees of the vertical lines.

In a fifth embodiment, the present disclosure provides a coated abrasive disc according to any one of the first to fourth embodiments, wherein the abrasive layer further comprises crushed abrasive or non-abrasive particles.

In a sixth embodiment, the present disclosure provides a coated abrasive disc according to any one of the first to fifth embodiments, wherein the disc backing comprises vulcanized fiber.

In a seventh embodiment, the present disclosure provides a coated abrasive disc according to any one of the first to sixth embodiments, wherein the abrasive layer comprises a make layer and a size layer disposed over the make layer and the abrasive elements.

In an eighth embodiment, the present disclosure provides a coated abrasive disc according to any one of the first to seventh embodiments, wherein the triangular abrasive platelets comprise alpha alumina.

In a ninth embodiment, the present disclosure provides a method of abrading a workpiece, the method comprising frictionally contacting a portion of the abrasive layer of a coated abrasive disc according to any one of the first to eighth embodiments with the workpiece, and moving at least one of the workpiece and the coated abrasive disc relative to the other to abrade the workpiece.

In a tenth embodiment, the present disclosure provides a method of abrading a workpiece according to the ninth embodiment, wherein the workpiece comprises a mild steel weld, and wherein the abrasive layer contacts the mild steel weld.

In an eleventh embodiment, the present disclosure provides a method of making a coated abrasive disc, the method comprising:

-   -   disposing a curable make layer precursor on a major surface of a         disc backing;     -   adhering (e.g., contacting and/or embedding) abrasive elements         to the curable make layer precursor,         -   wherein the abrasive elements are disposed at contiguous             intersections of horizontal lines and vertical lines of a             rectangular grid pattern, wherein at least 70 percent             (preferably at least 75 percent, more preferably at least 80             percent, more preferably at least 85 percent, and more             preferably even at least 90 percent) of the intersections             have one of the abrasive elements disposed thereat,         -   wherein each of the abrasive elements has two triangular             abrasive platelets, wherein each of the triangular abrasive             platelets has respective top and bottom surfaces connected             to each other, and separated by, three sidewalls, wherein,             on a respective basis, one sidewall of at least 90 percent             of the triangular abrasive platelets is disposed facing and             proximate to the disc backing,         -   wherein the abrasive elements are arranged such that the             triangular abrasive platelets in orthogonally adjacent             abrasive elements have a Z-axis rotational orientation             within 10 degrees of perpendicular to each other;     -   disposing a curable size layer precursor over the at least         partially cured make layer precursor and triangular abrasive         platelets; and     -   at least partially curing the curable size layer precursor to         provide a size layer.

In a twelfth embodiment, the present disclosure provides a method according to the eleventh embodiment, wherein at least 80 percent of the intersections have one of the abrasive elements disposed thereat.

In a thirteenth embodiment, the present disclosure provides a method according to the eleventh or twelfth embodiment, wherein, on a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing, wherein the triangular abrasive platelets disposed adjacent to alternating intersections along each horizontal line have a Z-axis rotational orientation within 5 degrees of the horizontal lines, and wherein the triangular abrasive platelets disposed adjacent to alternating intersections along each vertical line have a Z-axis rotational orientation within 5 degrees of the vertical lines.

In a fourteenth embodiment, the present disclosure provides a method according to the eleventh or twelfth embodiment, wherein, on a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing, wherein the triangular abrasive platelets disposed adjacent to alternating intersections along each horizontal line have a Z-axis rotational orientation within 2 degrees of the horizontal lines, and wherein the triangular abrasive platelets disposed adjacent to alternating intersections along each vertical line have a Z-axis rotational orientation within 2 degrees of the vertical lines.

In a fifteenth embodiment, the present disclosure provides a method according to any one of the eleventh to fourteenth embodiments, wherein the abrasive layer further comprises crushed abrasive or non-abrasive particles.

In a sixteenth embodiment, the present disclosure provides a method according to any one of the eleventh to fifteenth embodiments, wherein the disc backing comprises vulcanized fiber.

In a seventeenth embodiment, the present disclosure provides a method according to any one of the eleventh to sixteenth embodiments, wherein the triangular abrasive platelets comprise alpha alumina.

Objects and advantages of this disclosure are further illustrated by the following non-limiting examples, but the particular materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this disclosure.

EXAMPLES

Unless otherwise noted, all parts, percentages, ratios, etc. in the Examples are by weight. Unless stated otherwise, all other reagents were obtained, or are available from fine chemical vendors such as Sigma-Aldrich Company, St. Louis, Mo., or may be synthesized by known methods.

TABLE 1 ABBREVIATION DESCRIPTION AP1 Shaped abrasive particles prepared according to the disclosure of U.S. Pat. No. 8,142,531 (Adefris et al.). The shaped abrasive particles were prepared by molding alumina sol gel in equilateral triangle-shaped polypropylene mold cavities of side length 0.11 inch (2.794 mm) and a mold depth of 0.037 inch (0.931 mm). After drying and firing, the resulting shaped abrasive particles were about 1.4 mm (side length) × 0.47 mm thick, with a draft angle approximately 98 degrees, and would pass through an 18-mesh USA Standard Testing Sieve. AP2 Shaped abrasive particles were prepared according to the disclosure of U.S. Pat. No. 8,142,531 (Adefris et al.). The shaped abrasive particles were prepared by molding alumina sol gel in equilateral triangle-shaped polypropylene mold cavities of side length 0.11 inch (2.794 mm) and a mold depth of 0.028 inch (0.711 mm). After drying and firing, the resulting shaped abrasive particles were about 1.4 mm (side length) × 0.35 mm thick, with a draft angle approximately 98 degrees, and would pass through a 20-mesh USA Standard Testing Sieve. AP3 Shaped abrasive particles were prepared according to the disclosure of U.S. Pat. No. 8,142,531 (Adefris et al.). The shaped abrasive particles were prepared by molding alumina sol gel in equilateral triangle-shaped polypropylene mold cavities of side length 0.11 inch (2.794 mm) and a mold depth of 0.022 inch (0.559 mm). After drying and firing, the resulting shaped abrasive particles were about 1.4 mm (side length) × 0.28 mm thick, with a draft angle approximately 98 degrees, and would pass through a 20-mesh USA Standard Testing Sieve. AP4 Natural Almandite garnet conforming the ANSI standard for grade 50 (obtained as 50UT from Barton Abrasives, Glen Falls New York). AP5 Aluminum oxide conforming the FEPA (Federation of the European Producers of Abrasives) standard for P60 (obtained as DURALUM in grit size 60 from Washington Mills, Grafton, Massachusetts.

Example 1

A 7-inch (178-mm) circular plastic transfer tool having triangular cavities as shown in FIGS. 4 and 4A-4C was prepared by 3-D printing. Each repeat unit of the tool consisted of a pair of cavities oriented with their long axes parallel forming a square unit cell with side dimensions of 0.08 inch (2.03 mm). The cavities in adjoining unit cells were rotated 90 degrees in all four array directions. This pattern was repeated over the surface of the entire tool for a cavity density of 312 cavities per square inch (48.4 cavities per cm2). The transfer tool was treated with a molybdenum sulfide spray lubricant (obtained under the trade designation MOLYCOAT from the Dow Corning Corporation, Midland, Mich.) to assist abrasive grain release.

An excess of abrasive grain AP1 was applied to the surface of the transfer tool having the cavity openings and the tooling was shaken from side to side by hand. The transfer tooling cavities were soon filled with AP1 grains held in a vertex down and base up orientation and aligned along the cavity long axis. Additional AP1 was applied and the process repeated until greater than 95 percent of the transfer tooling cavities were filled by AP1 grain. Excess grain was removed from the surface of the transfer tool leaving only the grains contained within the cavities.

A make resin was prepared by mixing 49 parts resole phenolic resin (based-catalyzed condensate from 1.5:1 to 2.1:1 molar ratio of formaldehyde:phenol), 41 parts of calcium carbonate (HUBERCARB, Huber Engineered Materials, Quincy, Ill.), and 10 parts of water. 2.8 grams of make resin was applied via a brush to a 7-inch (17.8-cm) diameter×0.83 mm thick vulcanized fiber web (DYNOS VULCANIZED FIBER, DYNOS GmbH, Troisdorf, Germany) having a 0.875-inch (2.22-cm) center hole.

The AP1 filled transfer tool was placed cavity side up on a 7-inch (18-cm) by 7-inch (18-cm) square wooden board. The make resin coated surface of the vulcanized fiber disc was brought into contact with the filled transfer tool and another 7-inch by 7-inch (18 cm×18 cm) square wooden board was placed on top. The resulting assembly was inverted while being held in rigid contact and gently tapped to dislodge the AP1 grains from the transfer tool so as to fall base first onto the make resin surface. The vulcanized fiber disc backing was then allowed to fall away from the now substantially grain-free transfer tool resulting in an AP1 coated vulcanized fiber disc replicating the transfer tooling pattern.

A drop-coated filler grain consisting of AP5 was applied in excess to the wet make resin and agitated until the entire exposed make resin surface was filled to capacity with AP5. The disc was inverted to remove excess AP5. The amount of AP5 addition was 10.4+/−0.1 grams. The make resin was partially cured in an oven by heating for 45 minutes at 70° C., followed by 45 minutes at 90° C., followed by 3 hours at 105° C.

Example 2

EXAMPLE 2 was prepared by the method of EXAMPLE 1, with the exception that AP2 grain was used instead of AP1 grain.

Example 3

EXAMPLE 3 was prepared by the method of EXAMPLE 1, with the exception that AP3 grain was used instead of AP1 grain, the make resin weight was 3.2+/−0.2 grams, AP4 was used instead of AP5 and the size resin weight was 12.2+/−0.1 grams.

Comparative Example A

COMPARATIVE EXAMPLE A was a commercially available electro-coated vulcanized fiber disc made with AP2 abrasive particles (obtained under the trade designation 982C grade 36+, 3M Company, Saint Paul, Minn.).

Comparative Example B

COMPARATIVE EXAMPLE B was prepared generally as described in EXAMPLE 1. The transfer tool cavities were arranged in a square grid pattern where the radial orientation of the grains alternates by 90 degrees in both grid directions. The cavity array was 17 per inch (6.7 per cm) in both directions for a total cavity density of 289 per square inch (44.8 per square cm) or approximately 10950 cavities for the entire tool. This pattern has been described previously as Example 4 in U.S. Pat. No. 9,776,302 (Keipert). The transfer tool was filled with AP3 grain. The make resin amount was 3.5 grams. The drop coated secondary grain was 9.4 grams of AP4. The cryolite size resin level was 12.1 grams.

Comparative Example C

COMPARATIVE EXAMPLE C was prepared as described in EXAMPLE 1. The transfer tool pattern was a spiral pattern from center to edge where all of the cavity openings were oriented substantially edgewise with respect to the grinding direction of the rotating abrasive disc. The cavity spacing down the length of the spiral was approximately 9 per inch (3.5 per cm) and the spiral pitch was approximately 30 rows per inch (11.8 rows per cm). The total cavity density and number of cavities per disc was comparable to the transfer tools in EXAMPLE 1 and COMPARATIVE EXAMPLE B. The abrasive grain used was AP2. The amount of AP5 drop coated secondary grain was 11+/−0.1 grams and the amount of cryolite size resin was 13.7+/−0.1 grams

Grinding Test Method

The grinding performance of the various discs was evaluated by grinding 1018 mild carbon steel using the following procedure. Seven-inch (17.8-cm) diameter abrasive discs for evaluation were attached to an automated servo-motor rotary grinder set to operate at a constant rotational speed of 5000 rpm and fitted with a 7-inch (17.8 cm) ribbed disc pad face plate ((051144 EXTRA HARD RED RIBBED, obtained from 3M Company). The torque experienced by the grinder was measured during the test. The grinder was activated and urged against an end face of a 1×1 in (2.54×2.54 cm) pre-weighed 1018 steel bar under a starting load of 6 lb (2.7 kg). The workpiece was abraded under these conditions for 10-second grinding intervals (passes). After each grinding interval, the load was adjusted so as to maintain a constant torque measurement. Following each 10-second interval, the workpiece was allowed to cool to room temperature and weighed to determine the cut of the abrasive operation. Test results were reported as the incremental cut for each interval and the total cut removed. The test end point was determined when the cut fell below 25% of the initial cut value or the load reached 18 lb (8.2 kg). Total cut was reported with data truncated to the point where the grinding interval cut fell below 15 grams. Test results were reported as the incremental cut (g/cycle) for each interval and the total stock removed (g). Test results are reported in Table 2, below.

TABLE 2 COMPARATIVE COMPARATIVE COMPARATIVE EXAMPLE 1 EXAMPLE 2 EXAMPLE 3 EXAMPLE A EXAMPLE B EXAMPLE C Cycle Test 1 Test 2 Test 1 Test 2 Test 1 Test 2 Test 1 Test 2 Test 1 Test 1 Test 2 1 19.96 20.61 25.32 26.53 29.8 29.21 22.88 23.9 29.95 24.56 25.76 2 23.05 23.4 34.39 35.74 36.58 34.14 23.53 24.71 35.58 29.13 30.46 3 27.17 26.16 39.1 39.26 35.85 36.37 26.46 27.87 34.27 34.6 34.41 4 29.7 28.59 40.91 39.01 35.03 35.22 26.72 28.99 35.06 37.76 37.86 5 32.61 30.87 39.5 38.35 35.48 35.7 26.46 29.61 33.73 39.86 38.23 6 33.45 30.07 40.03 36.21 34.49 33.1 27.48 28.04 32.88 38.55 36.07 7 34.11 29.59 39.64 35.81 32.91 33.2 26.33 27.99 32.32 36.57 35.54 8 34.48 32.72 38.53 37.11 32.63 32.71 26.99 28.2 32.61 36.91 35.47 9 34.2 31.18 36.61 36.31 31.15 31.6 26.83 28.87 31.52 36.35 35.86 10 34.31 30.61 36.81 33.54 31.13 31.49 26.4 29.3 31.12 36.53 35.75 11 34.29 29.68 36.45 33.54 30.77 31.12 25.6 29.49 31.45 35.87 36.51 12 33.91 28.49 36.1 34.1 29.51 30.74 25.87 29.06 31.15 34.34 35.74 13 34.12 28.09 35.53 33.02 29.71 30.37 25.34 30.04 31.12 33.85 32.65 14 33.3 28.13 35.12 32.18 30.18 30.5 25.75 29.8 30.6 32.6 38.83 15 32.87 27.27 34.65 32.63 29.49 30.11 25.84 28.86 29.42 32.44 37.58 16 32.53 27.3 34.83 33.57 29.01 28.01 25.43 28.73 30.58 32.29 36.27 17 32.52 27.57 33.27 33.44 29.53 28.44 25.94 28.26 30.44 32.18 36.16 18 32.63 27.53 33.68 32.44 28.25 27.98 24.27 28.42 29.89 30.99 34.37 19 32.06 27.4 33.77 32.22 28.42 27.75 24.23 28.84 30.71 30.03 34.08 20 32.27 26.19 33.82 32.22 28.47 28.32 24.9 29.07 29.34 31.3 31.3 21 31.48 27.02 33.42 32.78 27.95 28.36 25.32 28.28 30.14 30.78 31.08 22 31.29 26.83 32.77 32.28 27.95 26.51 25.29 28.56 29.72 31.71 28.44 23 31.27 25.59 32.68 32.4 27.31 27.46 24.83 27.91 29.35 30.97 28.66 24 31.48 27.09 32.37 31.42 27.51 27.3 25.18 26.94 29.06 30.5 28.53 25 30.8 26.81 32.72 33.04 26.95 26.47 24.94 27.35 29.49 29.99 27.89 26 30.32 26.29 32.85 32.9 26.09 26.93 24.73 26.97 28.67 28.98 27.28 27 30.64 26.02 32.34 31.06 26.02 26.33 24.58 26.6 28.91 29.38 28.04 28 30.35 26.29 32.55 30.92 25.99 25.78 24.59 26.95 28.64 29.34 27.71 29 30.17 26.23 32.62 30.46 26.49 26.05 24.34 27.43 28.27 29.09 26.27 30 29.89 25.56 32.19 30.66 26.44 25.71 24.03 26.61 28.58 28.53 25.9 31 30.03 26.1 31.86 30.37 26.1 26.1 23.78 27.62 27.78 28.4 25.92 32 30.24 25.44 31.6 31.19 26.34 26.18 23.99 27.12 28.08 28.37 26 33 29.35 25.36 31.19 31.04 25.5 25.24 23.93 26.73 28.16 28.5 24.98 34 28.88 26.52 30.9 31.13 25.57 25.11 23.64 26.91 27.87 26.64 27.37 35 29.13 24.99 30.03 31.5 25.01 26.12 23.44 26.67 27.17 26.89 26.93 36 29.26 25.58 30.04 29.7 24.88 25.07 23.11 26.55 27.16 27.62 25.2 37 28.61 25.22 29.66 29.53 25.25 25.12 23.58 26.15 26.43 26.95 23.76 38 27.98 24.7 30.25 28.91 24.84 24.87 22.59 26.11 26.8 26.58 23.97 39 28.01 24.55 30.29 29.42 25.1 24.54 22.73 26.48 27.26 26.25 24.34 40 28.14 24.56 30.25 28.89 24.7 24.67 22.61 25.8 26.59 26.31 26.21 41 27.32 24.71 30.03 28.92 23.92 24.45 22.29 26.44 27.36 25.92 23.94 42 27.29 24.45 29.08 29.56 23.96 23.86 22.43 26.83 26.71 26.11 23.4 43 27.71 24.99 28.24 28.14 24 23.81 22.72 26.56 26.67 25.5 24.17 44 26.43 24.1 28.37 28.8 23.58 23.52 22.22 26.76 26.3 25.85 22.53 45 27.13 24.39 28.94 29.58 23.49 23.63 22.31 26.3 25.8 23.86 25.02 46 27 24.1 28.17 28.84 23.19 23.06 22.15 25.94 26.01 24.59 22.93 47 27.15 24.41 28.69 28.6 23.06 23.01 21.98 25.9 25.88 24.3 22.48 48 27.36 24.13 28.06 27.88 22.25 22.36 21.94 25.77 26.08 23.97 23.98 49 26.86 23.62 28.63 28.63 21.98 22.5 21.97 25.56 25.72 24.48 22.39 50 26.8 23.91 27.97 28.36 22.33 22.71 21.73 25.4 25.19 23.85 24.31 51 26.91 23.99 28.55 27.63 22.43 22.52 21.62 25.58 25.23 23.86 22.16 52 26.48 24.07 28.02 27.28 22.31 22.42 21.16 25.39 25.4 22.95 24.89 53 26.31 23.86 27.81 27.22 22.45 22.49 21.27 25.07 25.06 23.78 22.05 54 26.53 24.28 28.26 28.37 21.76 21.78 21.07 25.02 25.12 23.3 21.9 55 26.24 23.23 27.85 28.02 22.31 21.79 20.98 25.12 24.48 23.6 21.18 56 25.62 23.46 27.36 26.96 21.72 21.69 21.13 25.17 24.5 22.79 22.02 57 25.68 23.51 26.91 27.13 21.33 21.87 20.87 24.99 24.39 22.15 20.3 58 25.47 23.13 27.15 26.94 21.24 21.78 20.97 25.5 24.57 22.06 20.26 59 25.78 23.38 27.23 26.33 20.94 21.6 20.54 25.34 23.12 21.89 19.69 60 25.86 23.41 27.09 27.11 20.97 21.39 20.33 24.61 23.66 22.19 21.52 61 25.75 22.65 27.43 27.12 20.7 21.68 20.35 24.33 23.22 22.01 19.86 62 25.12 22.72 26.77 26.9 21.16 21.91 20.28 24.15 23.28 21.73 19.64 63 25.41 22.97 26.47 26.98 20.57 21.61 20.08 23.99 23.41 21.58 20.38 64 25.47 22.84 25.41 27.44 20.72 21.53 20.08 24.2 23.08 20.74 21.18 65 25.3 22.57 26.3 27.24 20.14 21.32 20.29 23.76 23.24 21.12 18.9 66 25.02 22.59 25.95 26.06 19.86 21.08 19.97 23.89 22.94 20.45 21.44 67 24.8 22.8 24.98 26.17 20.79 21.12 19.88 23.75 22.82 20.39 18.84 68 24.86 22.32 24.63 26.02 19.41 20.45 20.01 23.38 22.55 20.63 17.96 69 24.7 21.77 25.25 26.17 19.14 20.98 19.65 23.1 22.4 19.83 18.02 70 24.72 22.59 25.13 25.91 19.66 20.76 19.21 22.8 22.36 19.74 19.74 71 24.53 22.24 24.41 25.86 19.54 20.32 19.34 22.42 22.31 19.87 19.07 72 24.86 21.59 24.71 25.85 18.89 20.67 19.58 22.56 22.41 18.97 20.26 73 24.55 21.73 24.62 25.39 19.19 20.21 18.78 22.45 22.2 19.27 17.93 74 24.53 21.52 24.27 25.12 19.09 20.25 18.67 22.12 21.85 18.64 18.05 75 24.36 21.67 24.01 24.47 18.66 19.99 18.31 22.29 21.55 18.4 16.6 76 24.36 21.09 24.11 24.61 18.36 19.93 18.28 21.61 21.62 18.31 18.37 77 24.24 21.38 23.31 25.05 18.51 20.12 18.47 21.84 21.61 18.11 16.47 78 24.03 21.17 23.61 24.73 18.28 19.92 18.5 21.29 21.58 17.64 17.21 79 24.07 21.4 23.44 24.85 18.21 19.92 18.15 21.48 21.26 17.56 16.91 80 23.77 21.52 23.26 24.78 18.02 19.93 18.46 21.59 21.3 17.35 16.19 81 23.38 21.34 23.44 24.15 17.43 19.87 17.93 21.15 21.2 16.98 16.4 82 23.19 20.99 22.75 24.21 17.72 19.87 18.5 21.09 20.93 16.98 16.74 83 23.21 21.23 22.85 24.04 17.63 19.94 18.23 20.79 20.98 16.85 15.96 84 23.61 20.97 22.85 23.94 17.83 19.9 18.1 21.09 20.45 16.4 16.9 85 23.1 21.06 22.51 23.63 17.46 19.53 18.52 21.07 20.42 16.2 16.76 86 22.97 21.17 21.83 23.2 17.43 19.65 18.12 20.85 19.73 16.27 15.56 87 22.61 21.21 21.78 22.78 17.1 19.48 18.22 21.17 19.95 15.66 16.12 88 22.95 20.73 21.79 23.1 16.86 19.32 18.04 20.73 19.85 15.4 15.6 89 22.45 21.18 21.61 23.1 16.84 19.4 17.67 20.68 19.84 15.32 15.02 90 22.68 20.82 21.15 23.12 16.65 19.26 17.94 20.75 19.75 15.08 15.47 91 22.85 21.46 21.56 23.22 16.36 19.41 17.98 20.3 19.54 14.96 14.59 92 22.52 21.33 22.28 22.6 16.48 19.15 17.71 20.4 19.32 93 22.24 21.14 21.78 22.96 16.49 19.34 17.62 20.43 18.95 94 22.05 21.25 21.37 22.77 16.34 19.11 17.89 20 19.2 95 21.66 20.95 20.88 22.65 16.42 19.46 17.97 19.91 19.15 96 22.22 20.84 20.65 21.78 16.19 19.4 17.88 19.65 19.06 97 22 20.07 20.8 22.29 15.84 19.45 17.64 19.57 18.92 98 21.72 19.85 20.78 22.28 15.89 19 17.62 19.16 18.84 99 22.21 19.33 20.52 21.72 15.62 18.51 17.47 18.76 18.61 100 21.78 19.12 20.23 21.73 15.34 19.58 17.09 18.94 18.64 101 21.71 18.25 19.92 21.37 15.14 17.56 17.04 18.67 18.52 102 21.95 18.19 19.55 21.44 14.79 18.51 16.93 17.77 18.21 103 21.3 18.26 19.76 21.37 18.07 16.62 17.61 17.93 104 21.44 17.93 19.74 20.89 18.1 16.15 17.5 18.26 105 21.89 17.69 19.5 20.68 17.71 16.12 16.93 17.89 106 21.58 17.4 19.45 20.44 17.28 15.77 16.78 18.21 107 21.89 16.88 19.36 20.47 17.39 15.63 16.71 18.06 108 21.23 16.74 19.34 20 16.8 15.48 16.71 17.9 109 21.19 16.4 18.98 20.69 16.52 15.14 16.39 18.13 110 21.32 16.07 19.49 19.78 16.48 15.08 16.37 17.46 111 21.11 16.03 19.48 19.99 16.46 14.92 16.49 17.21 112 21.37 15.55 19.15 19.91 16.17 16.26 16.93 113 21.29 15.65 19.32 19.88 15.98 16.03 16.69 114 21.05 15.46 19.11 19.6 15.82 14.79 16.13 115 21.56 15.1 18.54 19.56 15.32 15.68 16.12 116 21.46 14.63 18.46 19.58 15.01 15.74 15.96 117 20.78 17.54 19.43 14.91 15.58 15.73 118 20.76 17.82 19.29 15.22 15.58 119 20.83 17.27 19.33 14.84 15.39 120 21.19 16.81 18.5 15.17 121 20.87 16.74 18.98 14.88 122 20.44 15.98 19.06 123 20.17 15.68 19.12 124 19.87 15.59 18.93 125 19.33 15.11 18.59 126 19.21 14.86 18.56 127 19 18.56 128 18.52 18.29 129 18.7 17.98 130 18.45 17.56 131 18.32 17.47 132 17.65 17.27 133 17.41 17.44 134 17.56 17.12 135 17.24 17.04 136 17.17 16.82 137 16.73 15.72 138 16.44 15.84 139 16.08 15.41 140 15.99 15.26 141 15.48 14.94 142 14.9 total 3531 2681 3317 3611 2352 2685 2345 2797 2902 2294 2233 cut

All cited references, patents, and patent applications in the above application for letters patent are herein incorporated by reference in their entirety in a consistent manner. In the event of inconsistencies or contradictions between portions of the incorporated references and this application, the information in the preceding description shall control. The preceding description, given in order to enable one of ordinary skill in the art to practice the claimed disclosure, is not to be construed as limiting the scope of the disclosure, which is defined by the claims and all equivalents thereto. 

1. A coated abrasive disc comprising: a disc backing; an abrasive layer disposed on the disc backing, wherein the abrasive layer comprises abrasive elements secured to a major surface of the disc backing by at least one binder material, wherein the abrasive elements are disposed at contiguous intersections of horizontal lines and vertical lines of a rectangular grid pattern, wherein at least 70 percent of the intersections have one of the abrasive elements disposed thereat, wherein each of the abrasive elements has two triangular abrasive platelets, wherein each of the triangular abrasive platelets has respective top and bottom surfaces connected to each other, and separated by, three sidewalls, wherein, on a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing, wherein the abrasive elements are arranged such that the triangular abrasive platelets in orthogonally adjacent abrasive elements have a Z-axis rotational orientation within 10 degrees of perpendicular to each other.
 2. The coated abrasive disc of claim 1, wherein at least 90 percent of the intersections have one of the abrasive elements disposed thereat.
 3. The coated abrasive disc of claim 1, wherein, on a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing, wherein the triangular abrasive platelets disposed adjacent to alternating intersections along each horizontal line have a Z-axis rotational orientation within 5 degrees of the horizontal lines, and wherein the triangular abrasive platelets disposed adjacent to alternating intersections along each vertical line have a Z-axis rotational orientation within 5 degrees of the vertical lines.
 4. The coated abrasive disc of claim 1, wherein the abrasive layer further comprises crushed abrasive or non-abrasive particles.
 5. The coated abrasive disc of claim 1, wherein the disc backing comprises vulcanized fiber.
 6. The coated abrasive disc of claim 1, wherein the abrasive layer comprises a make layer and a size layer disposed over the make layer and the abrasive elements.
 7. The coated abrasive disc of claim 1, wherein the triangular abrasive platelets comprise alpha alumina.
 8. A method of abrading a workpiece, the method comprising frictionally contacting a portion of the abrasive layer of a coated abrasive disc according to claim 1 with the workpiece, and moving at least one of the workpiece and the abrasive article relative to the other to abrade the workpiece.
 9. The method of claim 8, wherein the workpiece comprises a mild steel weld, and wherein the abrasive layer contacts the mild steel weld.
 10. A method of making a coated abrasive disc, the method comprising: disposing a curable make layer precursor on a major surface of a disc backing; adhering abrasive elements to the curable make layer precursor, wherein the abrasive elements are disposed at contiguous intersections of horizontal lines and vertical lines of a rectangular grid pattern, wherein at least 70 percent of the intersections have one of the abrasive elements disposed thereat, wherein each of the abrasive elements has two triangular abrasive platelets, wherein each of the triangular abrasive platelets has respective top and bottom surfaces connected to each other, and separated by, three sidewalls, wherein, on a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing, wherein the abrasive elements are arranged such that the triangular abrasive platelets in orthogonally adjacent abrasive elements have a Z-axis rotational orientation within 10 degrees of perpendicular to each other; at least partially curing the make layer precursor; disposing a curable size layer precursor over the at least partially cured make layer precursor and triangular abrasive platelets; and at least partially curing the curable size layer precursor to provide a size layer.
 11. The method of claim 10, wherein at least 90 percent of the intersections have one of the abrasive elements disposed thereat.
 12. The method of claim 10, wherein, on a respective basis, one sidewall of at least 90 percent of the triangular abrasive platelets is disposed facing and proximate to the disc backing, wherein the triangular abrasive platelets disposed adjacent to alternating intersections along each horizontal line have a Z-axis rotational orientation within 5 degrees of the horizontal lines, and wherein the triangular abrasive platelets disposed adjacent to alternating intersections along each vertical line have a Z-axis rotational orientation within 5 degrees of the vertical lines.
 13. The method of claim 10, wherein the abrasive layer further comprises crushed abrasive or non-abrasive particles.
 14. The method of claim 10, wherein the disc backing comprises vulcanized fiber.
 15. The method of claim 10, wherein the triangular abrasive platelets comprise alpha alumina. 